Cover window and apparatus and method for manufacturing the cover window

ABSTRACT

Provided are a cover window and an apparatus and method for manufacturing the cover window. The cover window includes a film layer having at least one bent portion, a resin layer having at least one bent portion, and an adhesive layer disposed between the film layer and the resin layer and adhering the film layer and the resin layer.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a Divisional of U.S. patent application Ser. No.14/057,536 filed on Oct. 18, 2013, and claims priority from and thebenefit of Korean Patent Application No. 10-2013-0073312, filed on Jun.25, 2013, which is hereby incorporated by reference for all purposes asif fully set forth herein.

BACKGROUND

Field

Exemplary embodiments of the present disclosure relate to a cover windowand an apparatus and method for manufacturing the cover window.

Discussion of the Background

Recently, various mobile electronic devices are being widely used.Examples of mobile electronic devices include tablet personal computers(PCs) that have become widely popular in recent years, as well as smallelectronic devices such as mobile phones, smartphones, and the like.

Such mobile electronic devices include a display unit for providingvisual information, such as images and video, to users so as toimplement various functions the devices possess. When it comes todisplay units, components for driving a display unit have beendownsized, and display units and their functions have been one of themost important features of the electronic devices. For example, displayunits that can be bent at a set angle have been manufactured.

In current technology, display units can be made flexible and bendable.Typically, a cover window may be attached to the outer surface of thedisplay unit to protect the exterior of the display unit. The coverwindow may be formed of various materials. For example, the cover windowmay be formed of a glass material or a synthetic resin. The cover windowmay be injection-molded by using a synthetic resin material. However,when a cover window is manufactured by injection molding, it is prone todelamination or deformation, which can be often detected when thereliability thereof is examined.

SUMMARY

Exemplary embodiments of the present disclosure provide a cover windowthat can be easily manufactured and is rigid, and an apparatus andmethod for manufacturing the cover window.

According to one exemplary embodiment of the present invention, there isprovided a cover window including: a film layer having at least one bentportion; a resin layer having at least one bent portion; and an adhesivelayer interposed between the film layer and the resin layer and toattach the film layer and the resin layer to each other.

In accordance with one exemplary embodiment, there is provided anapparatus for manufacturing a cover window, comprising: a first movingunit configured to retain a first member comprising at least one bentportion; a second moving unit spaced apart from the first moving unitand configured to retain a second member; and a driving unit configuredto linearly move at least one of the first moving unit and the secondmoving unit to laminate the first member and the second member, one ofthe first member and the second member comprising a resin layer, and theother comprising at least one of a film layer and a protection layer.

In accordance with one exemplary embodiment, there is provided a methodof manufacturing a cover window, comprising: mounting on a first movingunit a first member comprising at least one bent portion; disposing atleast a portion of a second member on a second moving unit so as to facethe first moving unit; and laminating the first member and the secondmember by linearly moving at least one of the first moving unit and thesecond moving unit, wherein one of the first member and the secondmember comprises a resin layer, and the other one of the first memberand the second member comprises at least one of a film layer and aprotection layer.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory and areintended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other features and aspects of the present invention willbecome more apparent by describing in detail exemplary embodimentsthereof with reference to the attached drawings.

FIG. 1 is a cross-sectional view illustrating a cover window accordingto one exemplary embodiment of the present invention.

FIG. 2 is a cross-sectional view illustrating an apparatus formanufacturing the cover window illustrated in FIG. 1, according to oneexemplary embodiment of the present invention.

FIG. 3 is a cross-sectional view illustrating an apparatus formanufacturing the cover window illustrated in FIG. 1, according to oneexemplary embodiment of the present invention.

FIG. 4 is a cross-sectional view illustrating an apparatus formanufacturing the cover window illustrated in FIG. 1, according to oneexemplary embodiment of the present invention.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Embodiments of the present invention are described in detail herein withreference to the accompanying drawings so that this disclosure may beeasily performed by one of ordinary skill in the art to which thepresent invention pertains. The present invention may, however, beembodied in different forms and should not be construed as being limitedto the embodiments set forth herein. Rather, these embodiments areprovided so that this disclosure will be thorough and complete, and willfully convey the scope of the present invention to those of ordinaryskill in the art. Furthermore, the present invention is only defined bythe scope of the claims. In the following description, technical termsare used only to explain a specific exemplary embodiment while notlimiting the present invention. The terms in a singular form may includeplural forms unless referred to the contrary. The terms “include”,“comprise”, “including”, and “comprising” as used herein, specify acomponent, a process, an operation, and/or an element but do not excludeother components, processes, operations, and/or elements. It will beunderstood that although the terms “first” and “second” are used hereinto describe various elements, these elements should not be limited bythese terms. These terms are only used to distinguish one component fromother components.

In the drawings, the thickness of layers, films, panels, regions, etc.may be exaggerated for clarity. Like reference numerals designate likeelements throughout the specification. It will be understood that whenan element such as a layer, film, region, or substrate is referred to asbeing “on” another element, it can be directly on the other element orintervening elements may also be present. In contrast, when an elementis referred to as being “directly on” another element, there are nointervening elements present. Expressions such as “at least one of,”when preceding a list of elements, modify the entire list of elementsand do not modify the individual elements of the list. It will beunderstood that for the purposes of this disclosure, “at least one of X,Y, and Z” can be construed as X only, Y only, Z only, or any combinationof two or more items X, Y, and Z (e.g., XYZ, XYY, YZ, ZZ).

FIG. 1 is a cross-sectional view illustrating a cover window 100according to one exemplary embodiment of the present invention. FIG. 2is a cross-sectional view illustrating an apparatus 200 formanufacturing the cover window 100 illustrated in FIG. 1, according toone exemplary embodiment of the present invention.

Referring to FIGS. 1 and 2, the cover window 100 may include a filmlayer 110. The film layer 110 may include a film body (not shown) and ashielding layer (not shown) disposed on at least one portion of the filmbody. The shielding layer may be provided to shield the film body fromlight coming from the outside. Hereinafter, for ease of description, thedescription will focus on an exemplary embodiment in which a shieldinglayer is not formed on the film body of the film layer 110.

In accordance with one exemplary embodiment, the film layer 110 may haveat least one bent portion. The film layer 110 may be bent in variousforms. For example, the film layer 110 may have a curved surface with aset radius of curvature. The film layer 110 may have only one bentportion. For example, the film layer 110 may have a flat shape, exceptedges thereof. That is, only the edges of the film layer 110 may bebent. Here, both side edges of the film layer 110 may be bent.Alternatively, only one side edge of the film layer 110 may be bent.

Furthermore, the film layer 110 may have a plurality of curved surfaceshaving different radii of curvature. More specifically, the film layer110 may have first to N-th curved surfaces having first to N-th radii ofcurvature (where N is a natural number). In accordance with oneexemplary embodiment, the first to N-th curved surfaces may be connectedto each other.

However, the film layer 110 is not limited to the above described forms.As long as at least one portion of the film layer 110 is bent, the filmlayer 110 may have any form.

Also, the bent portion of the film layer 110 may be a portion that isbent in at least one of a length direction and a width direction. Morespecifically, the film layer 110 may be bent in the length or widthdirection. Alternatively, the film layer 110 may be bent in both lengthand width directions.

Hereinafter, for ease of description, exemplary embodiments where onlyedge portions of the film layer 110 are bent will be described indetail. In addition, for ease of description, the film layer 110 ofwhich both side edges are bent in the width direction will be describedin detail.

The film layer 110 may be bent in various directions. For example, thefilm layer 110 may have an upwardly convex shape as seen in FIG. 1.Alternatively, the film layer 110 may have a downwardly convex shape.However, hereinafter, for ease of description, the film layer 110 havingthe upwardly convex shape, as shown in FIG. 1, will be described indetail.

In accordance with one exemplary embodiment, the film layer 110 may beformed of a transparent material. For example, the film layer 110 may beformed of at least one of polymethylmethacrylate (PMMA), polycarbonate(PC), polyethylene terephthalate (PET), polyethylene terephthalateglycol (PETG), and acrylonitrile butadiene styrene (ABS). The materialmay be provided as a resin to form the film layer 110. The film layer110 is not limited to the above-described materials and may include anyinjection-moldable transparent materials.

The shielding layer formed on the film body may be manufactured by aninkjet printing method, a silk screen printing method, an imprintmethod, or the like. Since the inkjet printing method, the silk screenprinting method, the imprint method, and the like can be employed in aconventional manner, detailed descriptions thereof will be omitted. Themethod of manufacturing the shielding layer is not limited to theabove-described methods. For example, the method may include any methodsof forming an opaque layer on the film body.

As described above, the shielding layer may be disposed on at least oneportion of the film layer 110. In particular, the shielding layer may bedisposed on the edge of the film layer 110.

In accordance with one exemplary embodiment, the cover window 100 mayinclude a resin layer 120 having at least one bent portion. The resinlayer 120 may have substantially the same shape as that of the filmlayer 110. In detail, if at least one portion of the film layer 110 isbent, at least one portion of the resin layer 120 may also becorrespondingly bent conforming to the film layer 110. The curvedsurface of the film layer 110 may have a radius of curvature that issimilar to that of the resin layer 120.

In accordance with one exemplary embodiment, the resin layer 120 may beformed of a transparent material. For example, the resin layer 120 mayinclude at least one of polymethylmethacrylate (PMMA), polycarbonate(PC), polyethylene terephthalate (PET), polyethylene terephthalateglycol (PETG), and acrylonitrile butadiene styrene (ABS). Here, thematerial may be provided as a resin and subsequently injected to formthe resin layer 120. Also, the resin layer 120 is not limited to theabove-described materials and may include any injection-moldabletransparent materials. The resin layer 120 and the film layer 110 may beformed of different materials or the same material.

The cover window 100 may include an adhesive layer 140 that isinterposed between the film layer 110 and the resin layer 120 andattaches the film layer 110 to the resin layer 120. The adhesive layer140 may include an optical clear adhesive (OCA). However, the adhesivelayer 140 is not limited thereto, and may include any material that isinterposed between the film layer 110 and the resin layer 120 andattaches the film layer 110 to the resin layer 120.

At least two of the film layer 110, the adhesive layer 140, and theresin layer 120 may have different sizes. More specifically, the filmlayer 110 and the adhesive layer 140 may have different sizes. Also, thefilm layer 110 and the resin layer 120 may have different sizes. Theadhesive layer 140 and the resin layer 120 may have different sizes.Also, the film layer 110, the adhesive layer 140, and the resin layer120 may all have different sizes. In particular, the film layer 110, theadhesive layer 140, and the resin layer 120 may have sizes that reducein that order. Accordingly, when the film layer 110, the adhesive layer140, and the resin layer 120 are assembled, the corresponding edges ofthe film layer 110, the adhesive layer 140, and the resin layer 120 mayfit with one another.

The cover window 100 may include a protection layer 130 formed on thefilm layer 110. The protection layer 130 may be formed on the film layer110 to oppose the resin layer 120 (i.e., to be disposed on the oppositeside of the cover window 100). More specifically, when the adhesivelayer 140 is formed on a first external surface 110 a of the film layer110, the protection layer 130 may be formed on a second external surface110 b of the film layer 110 that is different from the first externalsurface 110 a. On the other hand, as shown in FIG. 1, when the adhesivelayer 140 is formed on the second external surface 110 b, the protectionlayer 130 may be formed on the first external surface 110 a. However,for ease of description, the description made below will focus on anexemplary embodiment in which the protection layer 130 is formed on thefirst external surface 110 a, and the adhesive layer 140 is formed onthe second external surface 110 b.

The protection layer 130 may be formed of a material having functionssuch as protecting the underlying object from an external force, foreignsubstances, and static electricity. More specifically, the protectionlayer 130 may be formed of an acrylic material. Also, the protectionlayer 130 may be formed of a complex layer including an organic materialand an inorganic material. The protection layer 130 may be formed as afilm and attached on the film layer 110, and may also be formed using acoating method. However, for ease of description, the description belowwill focus on an exemplary embodiment in which the protection layer 130is formed as a film and attached on the film layer 110.

Accordingly, as the cover window 100 may have various forms, the coverwindow 100 may be used with a flexible display panel to manufacturevarious electronic devices. Moreover, although the cover window 100maintains a bent form, the film layer 110 and the resin layer 120 willhardly be separated because the film layer 110 and the resin layer 120are attached to each other by the adhesive layer 140.

Referring to FIG. 2, the apparatus 200 for manufacturing the coverwindow 100 as described above may include a first moving unit 210 inwhich a first member (not shown) is disposed, and at least a portion ofthe first member is bent. Also, the apparatus 200 may include a secondmoving unit 220 that is spaced apart from the first moving unit 210 andin contact with a portion of a second member (not shown). The firstmoving unit 210 may include a first jig (not shown), and the secondmoving unit 220 may include a second jig (not shown). More specifically,the second jig may be disposed to face the first jig.

A portion of the first moving unit 210 and a portion of the secondmoving unit 220 may be formed in substantially the same form as at leastone of the first member and the second member, respectively. Forexample, when the first member is bent, a recess may be formed in thefirst moving unit 210 or a portion of the first moving unit 210 mayprotrude so that the first moving unit 210 may completely contact theexternal surface of the first member. Moreover, a portion of the secondmoving unit 220 may protrude or a recess may be formed in the secondmoving unit 220 such that second moving unit 220 has a similar shape tothe first moving unit 210 having a recess or a protrusion. However, forease of description, the description below will focus on an exemplaryembodiment in which a portion of the first moving unit 210 protrudes,and a recess is formed in the second moving unit 220.

In accordance with one exemplary embodiment, at least one of the firstmoving unit 210 and the second moving unit 220 may include an aligningunit 230. The aligning unit 230 may include an align pin 231 that isformed on one of the first moving unit 210 and the second moving unit220 and an align groove 232 that is formed on the other one of the firstmoving unit 210 and the second moving unit 220, and the align pin 231 isinserted into the align groove 232. However, the aligning unit 230 isnot limited thereto, and may be any structure or device that aligns thefirst moving unit 210 with the second moving unit 220 when at least oneof the first moving unit 210 and the second moving unit 220 moves, suchas in a linear direction.

In accordance with one exemplary embodiment, the apparatus 200 formanufacturing a cover window may include a driving unit (for example,first and second driving units 241 and 242) which allows at least one ofthe first moving unit 210 and the second moving unit 220 to move, suchas in a linear direction, so as to laminate the first and secondmembers. Further, in accordance with one exemplary embodiment, one ofthe first and second members may include the resin layer 120, and theother one of the first and second members may include at least one ofthe film layer 110 and the protection layer 130. However, for ease ofdescription, the description below will focus on an exemplary embodimentin which the first member include the resin layer 120, and the secondmember include the film layer 110 and the protection layer 130.

The driving unit may have various forms. For example, the driving unitmay include a cylinder (not shown), a motor (not shown), and a gear unit(not shown). However, for ease of description, the description belowwill focus on an exemplary embodiment in which the driving unit includesa cylinder.

The driving unit may include at least one of a first driving unit 241that is connected to the first moving unit 210 to linearly move thefirst moving unit 210 and a second driving unit 242 that is connected tothe second moving unit 220 to linearly move the second moving unit 220.However, for ease of description, the description below will focus on anexemplary embodiment in which both the first and second driving units241 and 242 are included.

The apparatus 200 for manufacturing a cover window may include a firstfixing unit 251 that is installed on the first moving unit 210 to fixthe resin layer 120. Also, the apparatus 200 may include a second fixingunit 252 that is installed on the second moving unit 220 to fix the filmlayer 110 and the protection layer 130.

The first fixing unit 251 and the second fixing unit 252 may have asimilar form. More specifically, the first fixing unit 251 may include afirst vacuum hole (not shown) that is formed to pass through the firstmoving unit 210 and a first pump (not shown) that is connected to thefirst vacuum hole to absorb the air through the first vacuum hole. Also,the first fixing unit 251 may include a first adhesion chuck (not shown)that is installed on an external surface of the first moving unit 210.The first adhesion chuck may include at least one of a first adhesivefilm (not shown) and a first urethane sheet (not shown). Morespecifically, protrusions may be formed on at least one of the firstadhesive film and the first urethane sheet so as to increase itsadhesive force.

Like the first fixing unit 251, the second fixing unit 252 may include asecond vacuum hole (not shown) that is formed to pass through the secondmoving unit 220 and a second pump (not shown) that is connected to thesecond vacuum hole. Also, the second fixing unit 252 may include asecond adhesion chuck (not shown), and the second adhesion chuck mayinclude at least one of a second adhesive film (not shown) and a secondurethane sheet (not shown). Protrusions may be formed on at least one ofthe second adhesive film and the second urethane sheet to increase itsadhesive force.

Hereinafter, for ease of description, the description below will focuson an exemplary embodiment in which the first and second fixing units251 and 252 include the first and second adhesion chucks, respectively.

According to a method of manufacturing the cover window 100 as describedabove, the film layer 110 formed of at least one of the materials asdescribed above may be formed. If the film body and the shielding layerare to be formed, the film body may be formed first, and the shieldinglayer may be formed on at least a portion of the film body, forinstance, by using an inkjet printing method, a silk screen method, oran imprinting method. Because the inkjet printing method, the silkscreen method, or the imprinting method may be employed in aconventional manner, the detailed description thereof is omitted.

When the above-described operation is completed, the protection layer130 may be formed on the film layer 110. As described above, theprotection layer 130 may be formed as a film and attached on the filmlayer 110. Instead of a film, the protection layer 130 may also beformed using a coating method as described above. More specifically, theprotection layer 130 may be formed of an acrylic material or byalternately stacking an organic material and an inorganic materialdescribed above by using a spray method or a dip-coating method. Becausethe spray method or the dip-coating method can be employed in aconventional manner, the description thereof is omitted.

The protection layer 130 formed as described above according to oneexemplary embodiment can protect the external surface of the film layer110 from an external force, foreign substances, static electricity, orthe like.

When the above-described operation is completed, the film layer 110, onwhich the protection layer 130 is formed, may be disposed on the secondmoving unit 220. The film layer 110, on which the protection layer 130is formed, may be disposed in a flat state or may be bent and thendisposed on the second moving unit 220. More specifically, when the filmlayer 110 is disposed on the second moving unit 220 in a flat state, twoedges of the protection layer 130 may contact the second moving unit220, and the central portion of the protection layer 130 may beseparated from the surface of the second moving unit 220. On the otherhand, when the film layer 110 is bent, two edges and the central portionof the protection layer 130 may completely contact the surface of thesecond moving unit 220.

However, for ease of description, the description below will focus on anexemplary embodiment in which the film layer 110 in bent form isdisposed on the second moving unit 220.

The film layer 110 may be bent in various manners; the film layer 110may be bent by compressing or pressing the same by using a jig. Afterbending the film layer 110 as described above and disposing the same onthe second moving unit 220, the protection layer 130 may be fixed byusing the second fixing unit 252.

In accordance with one exemplary embodiment, the resin layer 120 may beformed prior to, during, or subsequent to the above-described procedureof preparing the film layer 110. More specifically, the resin layer 120may be manufactured by injecting a resin.

More specifically, a resin may be injected at a temperature in a rangefrom 200° C. to 300° C. Also, the resin may be injected into a moldhaving a bent form so that the resin layer 120 has a bent form.

The resin may be at least one of PMMA, PMMA, PC, PET, PETG, and ABS,which the resin layer 120 is formed of.

When the above-described operation is completed, the temperature may bereduced to harden the resin, thereby forming the resin layer 120. Whenthe above operation is completed, at least a portion of the resin layer120 may be bent.

The resin layer 120 that is bent as described above may be mounted onthe first moving unit 210. In accordance with one exemplary embodiment,a portion of the first moving unit 210 may be shaped to protrude,conforming to the bent external surface of the resin layer 120, andsupport the resin layer 120. Also, the first fixing unit 251 may fix theresin layer 120.

In accordance with one exemplary embodiment of the present invention,the adhesive layer 140 may be coated on the resin layer 120. Theadhesive layer 140 may be formed as a film like the film layer 110described above and may be attached on the external surface of the resinlayer 120. Here, the resin layer 120 coated with the adhesive layer 140may be disposed on the first moving unit 210, or after the resin layer120 is disposed on the first moving unit 210, the adhesive layer 140 maybe coated. However, for ease of description, the description below willfocus on an exemplary embodiment in which the adhesive layer 140 iscoated on the resin layer 120 after the resin layer 120 being disposedon the first moving unit 210.

When the adhesive layer 140 is completely coated, at least one of thefirst moving unit 210 and the second moving unit 220 is linearly movedto compress the resin layer 120 and the film layer 110, therebylaminating the resin layer 120 and the film layer 110. Morespecifically, when the first driving unit 241 and the second drivingunit 242 operate, the first moving unit 210 and the second moving unit220 may approach each other. Then, the first adhesive layer 140 on theresin layer 120 and the film layer 110 may contact each other, and theadhesive layer 140 and the film layer 110 may be attached to each otheraccording to the movement of the first moving unit 210 and the secondmoving unit 220. In particular, in the above-described embodiment of thepresent invention, the first driving unit 241 and the second drivingunit 242 may operate according to the appropriately set operating time,speed, and pressure.

When the above-described operation is completed, the first driving unit241 and the second driving unit 242 operate again to separate the firstmoving unit 210 and the second moving unit 220 from each other. The filmlayer 110 and the resin layer 120 are attached by the operation of thefirst and second moving units 210, 220, and may remain attached whilethe first moving unit 210 or the second moving unit 220 is moving.

When the operation of the first and second driving units 241 and 242 iscompleted, an operator may remove the protection layer 130, the filmlayer 110, the adhesive layer 140, and the resin layer 120, which areformed as a single body, from the first moving unit 210 or the secondmoving unit 220 to obtain the manufactured cover window 100.

The operator may take out the layers on his or her own or by using arobot arm included in the apparatus 200 for manufacturing a coverwindow. Also, the apparatus 200 may include a chamber 260 that cancreate vacuum inside when manufacturing the cover window 100. Moreover,the apparatus 200 may include a pressure adjusting unit 270 that isconnected to the chamber 260 and adjusts the inner pressure of thechamber 260. The pressure adjusting unit 270 may include a flow duct 271and a vacuum pump 272 connected to the flow duct 271. If the coverwindow 100 is manufactured in a vacuum chamber, fewer bubbles may begenerated when the film layer 110 and the resin layer 120 are laminated.

As such, by using the apparatus 200 for manufacturing a cover window andthe method of manufacturing a cover window as described above, the coverwindow 100 may be manufactured at room temperature, and thus deformationof the film layer 110 may be prevented. Also, by using the apparatus 200for manufacturing a cover window and the method of manufacturing a coverwindow, as the resin layer 120 having a small thickness is manufacturedin advance and laminated, the thickness of the cover window 100 may beeasily adjusted.

FIG. 3 is a cross-sectional view illustrating an apparatus 300 formanufacturing the cover window 100 illustrated in FIG. 1 according toanother embodiment of the present invention. Hereinafter, like referencenumerals as described above denote like elements.

Referring to FIG. 3, the apparatus 300 for manufacturing a cover windowmay include a first moving unit 310, a second moving unit 320, a firstfixing unit 351, a second fixing unit 352, a first driving unit 341, asecond driving unit 342, an aligning unit 330, a chamber 360, and apressure adjusting unit 370. The second moving unit 320, the firstfixing unit 351, the second fixing unit 352, the second driving unit342, the aligning unit 330, the chamber 360, and the pressure adjustingunit 370 are substantially the same as the second moving unit 220, thefirst fixing unit 251, the second driving unit 242, the aligning unit230, the chamber 260, and the pressure adjusting unit 270, respectively,and thus detailed descriptions thereof are not repeated.

The first moving unit 310 may include a first jig 311 and a drivingroller 312 that contacts the first jig 311 and makes a linear movementalong an external surface of the first jig 311. The driving roller 312may make a linear movement in a width direction or a length direction ofthe film layer 110.

Also, the first driving unit 341 may be connected to at least one of thefirst jig 311 and the driving roller 312 so that at least one of thefirst jig 311 and the driving roller 312 makes a linear movement. Inaccordance with one exemplary embodiment, the first driving unit 341 mayinclude a cylinder that is connected to at least one of the first jig311 and the driving roller 312. More specifically, the first drivingunit 341 may include a plurality of rollers that rotate the drivingroller 312 while being in contact with the driving roller 312, and amotor and a gear assembly that are connected to the plurality of rollersand linearly move the plurality of rollers while rotating the pluralityof rollers. However, for ease of description, the description below willfocus on an exemplary embodiment in which the first driving unit 341includes a cylinder, and the first driving unit 341 linearly moves onlythe driving roller 312.

The apparatus 300 for manufacturing a cover window may include a shaft380 that is connected to the second driving unit 342 and the secondmoving unit 320. The shaft 380 may be provided to make the second movingunit 320 rotatable. The first jig 311 and the second moving unit 320 maybe disposed at a predetermined angle. More specifically, the secondmoving unit 320 may be inclined with respect to the first jig 311. Forinstance, the second moving unit 320 may be rotated such that the secondmoving unit 320 forms an angle (e.g., acute, obtuse, and right) with thefirst jig 311. The shaft 380 may be configured to not only control theangle formed between the second moving unit 320 and the first jig 311,but also control the distance between them by moving the second movingunit 320 toward or away from the first jig 311. Further, in oneexemplary embodiment of the present invention, the second moving unit320 may include a second jig (not labeled).

In accordance with one exemplary embodiment using the apparatus 300 formanufacturing a cover window as described above, the film layer 110 maybe formed, and then the protection layer 130 may be formed on the filmlayer 110. The method of forming the protection layer 130 on the filmlayer 110 is substantially the same as described above, and thus adetailed description thereof is not repeated. In addition, as describedabove, the film layer 110 may be disposed on the second moving unit 320in a flat state or in a bent state. The method of fixing the film layer110 to the second moving unit 320 is substantially the same as describedabove, and thus a detailed description thereof is omitted. In addition,for ease of description, the description below will focus on anexemplary embodiment in which the film layer 110 in bent form isdisposed on the second moving unit 320.

While the above-described operation is performed, the resin layer 120may be formed and disposed on the first jig 311. The method of formingand disposing the resin layer on the first jig 311 is substantially thesame as described above, and thus a detailed description thereof isomitted. More specifically, when the resin layer 120 is disposed on thefirst jig 311, the adhesive layer 140 may be coated on the resin layer120. The method of coating the adhesive layer 140 and an order ofoperations of the method are substantially the same as described above,and thus a detailed description thereof is omitted.

When the resin layer 120 and the film layer 110 are disposed asdescribed above, the second driving unit 342 may be operated so that thefirst jig 311 and the second moving unit 320 approach each other. Whenthe film layer 110 and the adhesive layer 140 contact each other, thefirst driving unit 341 may linearly move the driving roller 312 along anexternal surface of the first jig 311.

More specifically, when the film layer 110 and the adhesive layer 140contact each other, the driving roller 312 may linearly move from aportion of the first jig 311 where the distance between the first jig311 and the second moving unit 320 is a first distance to anotherportion of the first jig 311 where the distance between the first jig311 and the second moving unit 320 is a second distance. In accordancewith one exemplary embodiment, the first distance may be smaller thanthe second distance. Further, the first distance may be equal to the sumof the thicknesses of the protection layer 130, the film layer 110, theadhesive layer 140, and the resin layer 120.

When the driving roller 312 operates as described above, the secondmoving unit 320 may continuously move. The driving roller 312 may movein connection with the movement of the second moving unit 320, while thesecond moving unit 320 may move according to the position of the drivingroller 312.

When the driving roller 312 operates as described above, and theadhesive layer 140 and the film layer 110 start to contact each other,the adhesive layer 140 and the film layer 110 may be laminatedcontinuously as the driving roller 312 linearly moves from the first endto the second end of the resin layer 120. More specifically, in theabove-described embodiment of the present invention, the adhesive layer140 and the film layer 110 are made attached continuously from the firstend to the second end of the resin layer 120, and thus fewer bubbles aregenerated between the adhesive layer 140 and the film layer 110.Moreover, when the chamber 360 is maintained in a vacuum by using thepressure adjusting unit 370, even fewer bubbles are generated betweenthe adhesive layer 140 and the film layer 110.

When the above-described operation is completed, the first jig 311 andthe second moving unit 320 are separated from each other to therebyseparate the protection layer 130, the film layer 110, the adhesivelayer 140, and the resin layer 120 from the first jig 311 or the secondmoving unit 320. The method of separating the layers is substantiallythe same as described above, and thus a detailed description thereof isomitted.

By using the apparatus 300 for manufacturing a cover window and themethod of manufacturing a cover window according to one exemplaryembodiment, the film layer 110 and the resin layer 120 may be laminatedquickly and easily, and also bubbles tend to be generated less oftenduring the lamination of the film layer 110 and the resin layer 120,thereby remarkably reducing defects in the manufactured cover window100.

In addition, using the apparatus 300 for manufacturing a cover windowand the method of manufacturing a cover window according to oneexemplary embodiment, the film layer 110 and the resin layer 120 may bemore rigidly coupled to each other, not only by compressing the firstmoving unit 310 and the second moving unit 320 but also by the drivingroller 312 pressing the first moving unit 310.

FIG. 4 is a cross-sectional view illustrating an apparatus 400 formanufacturing the cover window 100 illustrated in FIG. 1, according toone exemplary embodiment of the present invention. Hereinafter, likereference numerals as described above denote like elements.

Referring to FIG. 4, the apparatus 400 for manufacturing a cover windowmay include a first moving unit 410, a second moving unit 420, a firstfixing unit 451, a second driving unit 442, a chamber 460, and apressure adjusting unit 470. The first moving unit 410, the first fixingunit 451, the chamber 460, and the pressure adjusting unit 470 aresubstantially the same as the first moving unit 210, the first fixingunit 251, the chamber 260, and the pressure adjusting unit 270 describedwith reference to FIGS. 1 and 2, and thus a detailed description thereofis omitted.

The second moving unit 420 may include a lamination roller 421 thatcontacts at least a portion of at least one of the film layer 110 andthe protection layer 130 and linearly moves along the surface of atleast one of the film layer 110 and the protection layer 130. Thelamination roller 421 may laminate at least one of the film layer 110and the protection layer 130 with the resin layer 120.

Also, the second driving unit 442 may linearly move the laminationroller 421. More specifically, the second driving unit 442 may include afirst cylinder (not shown) that is connected to the lamination roller421 and linearly moves the same in a first direction, a plurality ofrollers 442 a that contact the lamination roller 421 to rotate the same,and at least one first motor 442 b and a first gear assembly 442 c thatare connected to the plurality of rollers 442 a and rotate the pluralityof rollers 442 a while linearly moving the plurality of rollers 442 a inthe first direction. However, for ease of description, the descriptionbelow will focus on an exemplary embodiment in which the second drivingunit 442 includes a plurality of rollers 442 a, a plurality of firstmotors 442 b, and a first gear assembly 442 c.

Also, the second driving unit 442 may include a second cylinder 442 dthat is connected to the lamination roller 421 and linearly moves thelamination roller 421 in a second direction that is different from thefirst direction. Also, the second driving unit 442 may include a secondmotor and a second gear assembly that are connected to the laminationroller 421 and linearly move the same in the second direction. Thesecond driving unit 442 may include a forcing unit (not shown) thatpushes the lamination roller 421 toward the first moving unit 410. Morespecifically, the forcing unit may include a material or an element suchas an elastic material or a spring that provides a restorative force tothe lamination roller 421. However, for ease of description, thedescription below will focus on an exemplary embodiment in which thesecond driving unit 442 includes the second cylinder 442 d.

The first direction and the second direction may be at a predeterminedangle with respect to each other. More specifically, the first directionmay be a length direction or a width direction of the resin layer 120,and the first direction and the second direction may be perpendicular toeach other.

In accordance with one exemplary embodiment using the apparatus 400 formanufacturing the cover window 100 as described above, the film layer110 may be formed, and then the protection layer 130 may be formed onthe film layer 110. The method of forming the protection layer 130 onthe film layer 110 is substantially the same as described above, andthus a detailed description thereof is omitted. Also, as describedabove, the film layer 110 may contact the lamination roller 421 in aflat state or a bent state.

However, for ease of description, the description below will focus on anexemplary embodiment in which the film layer 110 contacts the laminationroller 421 in a flat state.

While the above-described operation is performed, the resin layer 120may be formed and disposed on the first moving unit 210. The method offorming and disposing the resin layer 120 on the first moving unit 210is substantially the same as described above, and thus a detaileddescription thereof is omitted. More specifically, when the resin layer120 is disposed on the first moving unit 210, the adhesive layer 140 maybe coated on the resin layer 120. The method of coating the adhesivelayer 140 and the order of operations are the same as or similar to whatwas described above, and thus detailed descriptions thereof will beomitted.

When the resin layer 120 and the film layer 110 are disposed, the secondcylinder 442 d of the second driving unit 442 is operated to bring thelamination roller 421 into contact with the protection layer 130. Whenat least a portion of the film layer 110 and the adhesive layer 140contact each other, the plurality of first motors 442 b of the seconddriving unit 242 may linearly move the lamination roller 421.

More specifically, when at least a portion of the film layer 110 and theadhesive layer 140 contact each other, the lamination roller 421 maylinearly move along the external surface of the film layer 110. Morespecifically, the lamination roller 421 may move from a portion wherethe adhesive layer 140 and the film layer 110 contact each other to afirst end A of the resin layer 120 where the curvature radius of thebent portion of the resin layer 120 is the smallest. Also, after thelamination roller 421 has moved to the first end A of the resin layer120, the lamination roller 421 may linearly move again along the surfaceof the protection layer 130 to a second end B of the resin layer 120that is different from the first end A.

When the lamination roller 421 operates as described above, and theadhesive layer 140 and the film layer 110 start to contact each other,lamination work may be conducted as the lamination roller 421 linearlymoves from the first end of the resin layer 120 to the second end of theresin layer 120. More specifically, in the above-described embodiment ofthe present invention, a portion of the adhesive layer 140 and a portionof the film layer 110 continuously and increasingly contact each otherso as to effectively prevent bubbles from being generated between theadhesive layer 140 and the film layer 110. Moreover, when the chamber460 is maintained in a vacuum by using the pressure adjusting unit 470,even fewer bubbles tend to be generated between the adhesive layer 140and the film layer 110.

By using the apparatus 400 for manufacturing a cover window and themethod of manufacturing a cover window, the film layer 110 and the resinlayer 120 may be laminated quickly and easily. Moreover, fewer bubblesare generated during the lamination of the film layer 110 and the resinlayer 120, thereby remarkably reducing defects in the manufactured coverwindow 100.

According to various exemplary embodiments of the present invention, acover window may be manufactured by quickly and easily laminating thefilm layer and the resin layer. Also, according to various exemplaryembodiments of the present invention, as a cover window is formed atroom temperature, separation or deformation of the layers of the coverwindow can be prevented.

Moreover, according to various exemplary embodiments of the presentinvention, at least one portion of the cover window may be bent so as toprovide a better viewing angle in various directions.

While the present invention has been particularly shown and describedwith reference to exemplary embodiments thereof, it will be understoodby those of ordinary skill in the art that various changes in form anddetails may be made therein without departing from the spirit and scopeof the present invention as defined by the following claims.

What is claimed is:
 1. A cover window comprising: a film layercomprising at least one bent portion; a resin layer comprising at leastone bent portion; and an adhesive layer disposed between the film layerand the resin layer and adhering the film layer and the resin layer. 2.The cover window of claim 1, wherein at least two of the film layer, theadhesive layer, and the resin layer comprise different sizes.
 3. Thecover window of claim 1, further comprising a protection layer disposedon the film layer.
 4. A method of manufacturing a cover window, themethod comprising: disposing on a first moving unit a first membercomprising at least one bent portion; disposing at least a portion of asecond member on a second moving unit so as to face the first movingunit; and laminating the first member and the second member by linearlymoving at least one of the first moving unit and the second moving unit,wherein one of the first member and the second member comprises a resinlayer, and the other one of the first member and the second membercomprises at least one of a film layer and a protection layer.
 5. Themethod of claim 4, further comprising coating an adhesive layer on thefirst member before mounting the first member on the first moving unit.6. The method of claim 4, wherein: the first moving unit comprises afirst jig configured to dispose the first member; the second moving unitcomprises a second jig configured to dispose the second member; andlaminating the first member and the second member comprises: moving thefirst jig and the second jig while maintaining an angle with respect toeach other; and moving at least one of the first jig and the second jigin a direction perpendicular to the first member such that the firstmember and the second member contact from a first end to a second end ofthe first member to thereby laminate the first member and the secondmember.
 7. The method of claim 6, wherein: the first moving unit furthercomprises a driving roller disposed to contact at least a portion of thefirst jig; laminating the first member and the second member furthercomprises, when the first member and the second member start to contact,linearly moving the driving roller along an external surface of thefirst jig from the first end to the second end of the first memberaccording to a movement of at least one of the first jig and the secondjig.
 8. The method of claim 4, wherein: the second moving unit comprisesa lamination roller configured to contact at least a portion of thesecond member; and laminating the first member and the second memberfurther comprises linearly moving the lamination roller along anexternal surface of the second member to laminate the first member andthe second member.
 9. The method of claim 8, wherein linearly moving atleast one of the first moving unit and the second moving unit comprisesmoving the lamination roller to laminate the first member and the secondmember from a portion where the first member and the second membercontact, to a first end of the first member where a bent portion of thefirst member has the smallest curvature radius, and toward a second endof the second member that is different from the first end.
 10. Themethod of claim 4, wherein the laminating is performed in a vacuumenvironment.